Readily adjustable relay contact structure



Aug. 25, 1964 D. R. HAZELQUIST 3,146,315

READILY ADJUSTABLE RELAY CONTACT STRUCTURE Fild May 16, 1962 "Hul 1 i21% 54 F 9' Bomb 2 2x523 1315:- T '9 4 7% M United States Patent3,146,315 READILY ADJUSTABLE RELAY CONTACT STRUCTURE Donald R.Hazelquist, St. Louis Park, Minn, assignor to Minneapolis-HoneywellRegulator Company, Minneapolis, Minn., a corporation of Delaware FiledMay 16, 1962, Ser. No. 195,220 Claims. (Cl. 20087) The present inventionis directed to an electro-magnetically operated relay, and moreparticularly is directed to a relay having a unique type of contactstructure. The invention is further directed to a method ofmanufacturing the contact structure in a more economical fashion thanhas been previously available.

The relay art is a very highly developed art and as such is exceedinglycompetitive in nature. Any advantage which can be gained by theutilization of a particular type of relay structure or a method offabricating part of a relay structure or contact structure isexceedingly important in the commercial world. In the field of control,that is the switching of relatively small currents at varying voltages,it has been desirable to provide a relay structure that is reliable incontact action and also which can be manufactured at a reasonable cost.The present relay is directed both to a relay that provides reliablecontact action and also provides a method of fabricating the contactstructure that is exceedingly cheap and convenient.

It is a primary object of the present application to disclose a novelcontact structure for a relay and further to disclose a method ofmanufacturing the contact structure.

It is a further object of the present invention to disclose a contactstructure that can be readily adjusted and which adjustment remainsfixed after the adjustment has been made.

Still a further object of the present invention is to disclose a contactstructure that is exceedingly rigid because of its form and method ofmanufacture thereby providing a reliable contact structure.

These and other objects will become apparent when the drawings of thepresent application are considered, wherein:

FIGURE 1 is a side view of a clapper type of relay utilizing the presentinvention;

FIGURE 2 is an end view of the relay of FIGURE 1 from the end where thecontact structure is mounted;

FIGURE 3 is an elevation of a piece of the contact structure in a firststep in a method of manufacturing the contact structure;

FIGURE 4 is an assembled contact means prior to its mounting on amounting means of the relay of FIGURES 1 and 2, and;

FIGURE 5 is a partial view of the contact portion of FIGURE 4 wherein asilver overlay has been added to the contact areas for more reliableoperation.

The entire relay structure is shown in FIGURES 1 and 2. This relay isformed by a solid magnetic member that has a laminated leg 11 whichforms a fixed magnetic portion of the over-all magnetic circuit. Themagnetic circuit is completed by an armature 12 of magnetic materialthat is pivoted at 13 on a frame 14. The frame 14 extends upward at 15to form a hinge member for the armature 12 so that it can cooperatemagnetically and mechanically with the laminated leg 11. The laminatedleg 11 has a copper ring 16 embedded in it and ring 16 forms aconventional shading coil for the device.

Encircling the laminated leg 11 is a coil 20 that has a pair ofterminals 21 and 22 to which are connected the normal leads forenergizing the electric coil. The electric coil 20, when it is energizedfrom a normal source of 3,146,315 Patented Aug. 25, 1964 electric power,provides a magnetic flux that can flow in the magnetic circuit meansformed by the member 10, the laminated leg 11, and the armature 12. Thestructure described is conventional in the clapper type of relay andwarrants little or no further explanation.

A conventional tail spring 23 is connected between an end of thearmature 12 and the frame 14 at a point not shown. The frame 14 has anextension 24 that can be placed through a panel and bent over or crimpedto provide a mounting means for the relay. The frame 14 has tabs 25, 26and 27 that are bent around the magnetic member 10 to hold the device ina unitary form. A conductor 30 joins a rivet 31 electrically with theframe 14 at a point 32 so that the frame 14 becomes part of any electriccircuit to which the relay is connected. This is accomplished bywrapping a conductive wire 33 around the rivet 31 and allowing the wire33 to extend outwardly at 34 beyond the armature 12. It should beunderstood that the wire 33 is wrapped around the rivet 31 could bereplaced by any type of elongated contact means that would projectbeyond the armature 12 to the point 34 and which would form a part of anelectrical contact structure for the relay. The elongated contact meansor wire 33 is preferably somewhat flexible in nature so that goodalignment will be accomplished when the device is utilized, as will beseen later in the present disclosure.

An upstanding channel 35 is provided integrally with the frame 14 and isU-shaped in cross section. The U- shaped channel 35 has a bight portion36 and two upstanding channel members 37 and 38. A slot 40 is cut in thebight 36 and provides a means for mounting the novel contact structureof the present relay.

The novel contact structure of the present relay is formed by aninsulating member 41 that holds the contact means generally. Theinsulating member 41 is attached by rivets 42 and 43, with enlargedheads and 46, through the slot 40 along with a large frictional spacingmember 44. When the rivets 42 and 43 are placed through the frictionalmember 44 and properly flattened with heads at 47 and 48 on the backside of the insulator 41, a unitarily mounted contact structure isprovided. The insulating member 41 can he slid frictionally in the slot40 for adjustment purposes. The frictional engagement of member 44provides an adjustment feature. After the device is adjusted it normallywill retain its adjustment without further locking means. If theparticular relay is to be subjected to any unusual environmentalconditions, the adjusting or frictional member 44 can be further lockedby cements, ambroid, glues, or any similar material after the positionof the insulator 41 has been accomplished.

The insulator 41 carries a fixed contact means for the present deviceand the fixed contact means is made up of two L-shaped contact members50 and 51. The L- shaped member 50 has a plurality of tabs 52 that arecrimped or bent around a portion of the insulating member 41 by passingthe tabs 52 through holes 53 in the insulating member 41. Alsointegrally connected to the contact 50 is a terminal 54 that passesthrough an opening 55 in the insulated member 41.

The contact member 51 also has tabs 52 and a hole 53 in the insulator41. The tabs 52 are bent to hold the contact 51 is position also. Thecontact 51 further has a terminal 54 that passes through an opening 55in the insulator 41 as did the contact member 50.

The contact members 50 and 51 are stamped from a sheet of metal and theportions that are generally at right angles to one another are of asuflicient thickness to maintain the relationship of the parts in afixed manner so that the contact is not subject to bending or adjustmentafter the tabs 52 have been crimped or bent into place. The contact 50further has a contact surface 60 that is substantially parallel to thecontact surface 61 that is formed along the top edge of the contact 51.It will be noted that the wire 33 of the elongated contact means passesbetween the surfaces 6% and 61 and bears against the surface 60 when therelay is in a de-energized condition. When the relay is energized thewires 33 move downward in the space between the contact members 50 and51 to engage the surface 61 of contact 51. By adjusting the position ofthe insulating member 41, as previously described, the location of theopening between the surfaces 60 and 61 can be set for proper relayoperation. It will thus be noted that a single pole double throw relaycontact structure has been provided wherein the frame 14 of the relay iscommon between the contacts 50 and 51 which are electrically isolated onthe insulating member 41.

The description of the relay of FIGURES 1 and 2 has been made with thediscussion of the contacts 50 and 51 being separate movable contactmembers on a mounting means of an insulated type. In fabricating thisrelay the method of manufacturing the contacts 50 and 51 forms animportant part of the design and construction of the relay. In order toexplain this, FIGURES 3 and 4 will be considered. In fabricating thecontact structure for the relay a single contact member or structure ispunched or formed from a sheet of metal. This unitary contact structureis shown in FIGURE 3 with the contact 50 and the contact 51 joined at acorner 70. It will be noted that structurally the contacts 50 and 51 areinterconnected when the contact structure is initially formed. Thespacing and position of the contact surfaces 60 and 61 is established bythe design of the die which punches the contact structure disclosed inFIG- URE 3 from the sheet of metal. The tabs 52 are integrally formed tothe single contact structure member as are the terminals 54. After thecontact structure shown in FIGURE 3 has been punched out of a solidsheet of conductive material, the tabs 52 and the terminals 54 are bentperpendicular to the contact members 50 and 51. It wil be noted thatboth the contact members 50 and 51 are generally L-shaped in their c011-figuration and that they are interconnected only at the corner 70.

The next two steps in the assembly or manufacture of the contact sectionof the present relay are shown in FIGURE 4. The insulating member 41 isplaced over the structure disclosed in FIGURE 3 and the tabs 52 are bentover after passing through the holes 53 in the insulating member 41.After the tabs 52 are bent down or crimped, it will be obvious that thecontact structure and the insulating member form a rigidly mountedsingle contact structure. In order to electrically separate the twocontacts 50 and 51 the corner 70 is clipped off on a line 71 whichpasses through the corner 70 at approximately a 45 degree angle. Theseparation of the two contacts leaves two rigidly fixed contact membersthat are not subject to any type of bending or displacement afterassembly. In severing the corner of the contact structure theinterconnection has been removed and the two L-shaped members form twoelectrically independent relay contacts. The contact assembly disclosedin FIGURE 4 is then mounted by rivets 42 and 43 into place as has beenpreviously described. The adjustment is accomplished and the relay isready for operation.

Since one of the primary objects of the present relay is reliableswitching action, it will be noted that the elongated contact structurehas been shown as two wires 33. The two Wires provide redundant contactwith the surfaces 60 and 61 so that exceedingly small voltages can bereliably switched without the normal effects of dirt and deposits on thecontact surfaces. The elongated contact members 33 are quite flexibleand thereby adjust to the surfaces 60 and 61 to provide good contact. Inan improved version where exceedingly sensitive control is required, anarrangement disclosed in FIGURE 5 is utilized. The contact structuredisclosed in FIGURE 3 is punched from metal stock having a silveroverlay 72 that passes adjacent the surfaces 60 and 61, therebyproviding a silver edge on the contact surfaces 60 and 61. It will benoted that with the arrangement of FIGURE 5 the contact wires 33 passover the edge of the silver thereby giving an exceedingly reliablecontact structure that normally accomplishes the job of a silver orsimilar electrical overlay but without the expense of using silver orsimilar contact material on the entire structure.

It will be noted in this entire discussion that the contact structuredisclosed is an exceedingly rigid contact structure as far as themembers 50 and 51 are concerned. The members are of sufiicient thicknessand of such cross-section that they cannot be readily moved by bendingthe sections and therefore the control of the contact placement canreadily be accomplished in the punching operation. The contact surfaces60 and 61 can either be punched parallel to one another or in some otheralignment depending upon the type of contact operation desired. Whilethe contacts 50 and 51 could be made and aligned separately by manualmeans, this would defeat the advantage of the present structure. Thepresent relay is designed for substantially automatic production inexceedingly high volume and the cost saving in assembling a single partto the insulator 41 and then severing the part to provide the twocontact members is a substantial improvement in the manufacture of thistype of relay. The sections of metal involved are of suificient size sothat the contact surfaces 60 and 61 remain substantialy fixed throughoutthe life of the device and require no further adjustment in productionor use. It is obvious that many of the features of the present inventioncould be modified by one skilled in the art and the applicant wishes topoint out that only one of the preferred embodiments of the inventionhas been disclosed. As such, the applicant wishes to be limited in thescope of his invention only by the scope of the appended claims.

I claim as my invention:

1. In an electromagnetically actuated relay, comprising: magneticcircuit means including magnetic flux generating means for providing acontrolled magnetic flux in said circuit means; said circuit meansincluding a fixed magnetic member and a movable magnetic member whichmove relative to each other as said magnetic flux is controlled;elongated contact means carried by said movable magnetic member; fixedmetal contact means including two contacts of rectangular cross sectionhaving adjoining contact surfaces and each further having an integralextension at generally right angles to said contact surfaces; saidcontact surfaces and said extensions lying in a plane perpendicular toand intersected by said elongated contact means; and an insulatingmember attached to said extensions to mount said contact surfacesadjoining each other; said contacts and said extensions being integrallyformed of a metal of sufiicient thickness to maintain a fixedrelationship between said contacts after said contact means is mountedupon said insulating member; said insulating member mounted upon saidmagnetic circuit means to allow said elongated contact to pass betweensaid contact surfaces.

2. In an electromagnetically actuated relay, comprising: mounting meansand magnetic circuit means including magnetic flux generating means forproviding a controlled magnetic flux in said circuit means; said circuitmeans including a fixed magnetic member and a movable magnetic memberwhich move relative to each other as said magnetic flux is controlled;elongated contact means carried by said movable magnetic member; fixedmetal contact means including two contacts of rectangular cross sectionhaving adjoining substantially parallel contact surfaces and eachfurther having an integral extension at generally right angles to saidcontact surfaces; said contact surfaces and said extensions lying in aplane perpendicular to and intersected by said elongated contact means;and an insulating member attached to said extensions to mount saidcontact surfaces adjoining each other; said contacts and said extensionsbeing integrally formed of a metal of sufficient thickness to maintain afixed relationship between said contacts after said contact means ismounted upon said insulating member to maintain said substantiallyparallel relationship; said insulating member mounted upon said mountingmeans to allow said elongated contact to pass between said contactsurfaces.

3. In an electromagnetically actuated relay, comprising: a mountingframe and magnetic circuit means including an electrical coil forproviding a controlled magnetic flux in said circuit means; said circuitmeans including a fixed magnetic member and a movable magnetic armaturewhich move relative to each other as said magnetic flux is controlled;an elongated contact formed of at least two wires carried by saidmagnetic armature; fixed metal contact means including two rigidL-shaped contacts of rectangular cross section having adjoiningsubstantially parallel contact surfaces; both said L-shaped contactslying in a single plane perpendicular to and intersected by saidelongated contact; and an insulating member attached to a lower portionof said L-shaped contacts to mount said contact surfaces adjoining eachother; said contacts including said lower portions being formed of ametal of sufiicient thickness to maintatin a fixed relationship betweensaid contact surfaces after said contact means is mounted upon saidinsulating member to maintain said substantially parallel relationship;said insulating member mounted upon said mounting frame to allow saidelongated contact wires to pass between said contact surfaces.

4. In an electromagnetically actuated relay, comprising: mounting meansincluding sliding connection means; magnetic circuit means includingmagnetic flux generating means for providing a controlled magnetic fluxin said circuit means mounted upon said mounting means; said circuitmeans including a fixed magnetic member and a movable magnetic memberwhich move relative to each other as said magnetic flux is controlled;elongated contact means carried by said movable magnetic member; fixedmetal contact means including two contacts of rectangular cross sectionhaving adjoining contact surfaces and each further having an integralextension at generally right angles to said contact surfaces; saidcontact surfaces and said extensions lying in a plane perpendicular toand intersected by said elongated contact means; and an insulatingmember attached to said extensions to mount said contact surfacesadjoining each other; said contacts and said extensions being integrallyformed of a metal of sufficient thickness to maintain a fixedrelationship between said contacts after said contact mean-s is mountedupon said insulating member; said insulating member mounted upon saidmounting means by said sliding connection means to allow said elongatedcontact to pass between said contact surfaces; said sliding connectionmeans further providing for adjustment of the position of said elongatedcontact means with respect to said contact surfaces.

5. In an electromagnetically actuated relay, comprising: a mountingframe including sliding connection means; magnetic circuit meansincluding an electrical coil for providing a controlled magnetic flux insaid circuit means mounted upon said mounting means; said circuit meansincluding a fixed magnetic member and a movable magnetic armature whichmove relative to each other as said magnetic flux is controlled;elongated contact means carried by said movable magnetic armature; fixedmetal contact means including two rigid L-shaped contacts of rectangularcross section having adjoining substantially parallel contact surfaces;both said L-shaped contacts lying in a single plane perpendicular to andintersected by said elongated contact means; and an insulating memberattached to a lower portion of 'said L- shaped contacts to mount saidcontact surfaces adjoining each other; said contacts including saidlower portions being formed of a metal of suflicient thickness tomaintain a fixed relationship between said contact surfaces after saidcontact means is mounted upon said insulating member; said insulatingmember mounted upon said mounting means by said sliding connection meansto allow said elongated contact to pass between said contact surfaces;said sliding connection means further providing for adjustment of theposition of said elongated contact means with respect to said contactsurfaces.

References Cited in the file of this patent UNITED STATES PATENTS1,669,784 Scofield May 15, 1928 2,097,335 Memrnel Oct. 26, 19372,292,497 Vradenburgh Aug. 11, 1942 2,757,254 Wells July 31, 19562,854,545 Nemeth Sept. 30, 1958 3,012,117 Bernier Dec. 5, 1961 3,015,876Hutt Jan. 9, 1962 3,025,370 Greshel Mar. 13, 1962 3,071,844 Krause etal. Ian. 8, 1963

1. IN AN ELECTROMAGNETICALLY ACTUATED RELAY, COMPRISING: MAGNETICCIRCUIT MEANS INCLUDING MAGNETIC FLUX GENERATING MEANS FOR PROVIDING ACONTROLLED MAGNETIC FLUX IN SAID CIRCUIT MEANS; SAID CIRCUIT MEANSINCLUDING A FIXED MAGNETIC MEMBER AND A MOVABLE MAGNETIC MEMBER WHICHMOVE RELATIVE TO EACH OTHER AS SAID MAGNETIC FLUX IS CONTROLLED;ELONGATED CONTACT MEANS CARRIED BY SAID MOVABLE MAGNETIC MEMBER; FIXEDMETAL CONTACT MEANS INCLUDING TWO CONTACTS OF RECTANGULAR CROSS SECTIONHAVING ADJOINING CONTACT SURFACES AND EACH FURTHER HAVING AN INTEGRALEXTENSION AT GENERALLY RIGHT ANGLES TO SAID CONTACT SURFACES; SAIDCONTACT SURFACES AND SAID EXTENSIONS LYING IN A PLANE PERPENDICULAR TOAND INTERSECTED BY SAID ELONGATED CONTACT MEANS; AND AN INSULATINGMEMBER ATTACHED TO SAID EXTENSIONS TO MOUNT SAID CONTACT SURFACESADJOINING EACH OTHER; SAID CONTACTS AND SAID EXTENSIONS BEING INTEGRALLYFORMED OF A METAL OF SUFFICIENT THICKNESS TO MAINTAIN A FIXEDRELATIONSHIP BETWEEN SAID CONTACTS AFTER SAID CONTACT MEANS IS MOUNTEDUPON SAID INSULATING MEMBER; SAID INSULATING MEMBER MOUNTED UPON SAIDMAGNETIC CIRCUIT MEANS TO ALLOW SAID ELONGATED CONTACT TO PASS BETWEENSAID CONTACT SURFACES.